S C

Corona Supplies Ltd

for all your corona needs

Unit G, Howland Road Business Park, Thame, Oxon. OX9 3GQ. UK. Telephone: +44 (0) 1844 261779 ~ Fax: +44 (0) 1844 358187 ~ E-mail: sales@coronasupplies co.uk

GXR
GENERATORS
GX30R TO GX100R
INCLUDING GENERATOR & ELECTRODE MAINTENANCE

CONTENTS 1 2 3 Introduction Specification Installation 3.1 Generator 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 Mains Input (PL1 GX30R only) SK2 Underspeed Probe HT Output to Transformer (SK3 GX30R only) SK4 Interlocks/Skip Treat Function/Air Flow Switch PL5 Alarm Circuit Remote/Computer Interfacing

3.2 H.T. Transformer 3.3 Electrode Unit 3.3.1 Setting Nip Roll 3.3.2 Doweling of Nip Arms 3.3.3 Spreader Roll Adjustment 4 Operating Equipment 4.1 Setting electrodes 4.2 Initial Switch On 4.2.1 Operating procedure 4.3 Normal operation

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5 6 7

Matching the Generator to the Load Routine Maintenance Circuit Description 7.1 7.2 7.3 7.4 Circuit Overview Power Supply Major Interlocks Minor Interlocks 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 Line Speed Positive and Negative Mismatch Current Trip Auxiliary Shutdown Skip/Treat - Optional

7.5 Power Control 7.5.1 Manual 7.5.2 Proportional 7.5.3 Remote 7.6 Pulse Width Modulation (PWM) Circuit 7.7 True and Reactive power Measurement 7.7.1 Remote 8 Trouble Shooting & LED Arrays & SW1, SW2 & SW3 positions 8.1 8.2 Circuit Breaker Inverter Overtemp

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8.3

Tripping 8.3.1 8.3.2 8.3.3 8.3.4 Poor Match Incorrect Gap Fault in Electrode LED, SW1, SW2 & SW3 Positions

Drawings 9.1 9.2 9.3 Pneumatic Control Box (if fitted) Generator Circuit Diagram Generator PCB Sheets

10 11 12

Generator Parts List Electrode Unit Parts List Ozone: Health Hazards and Precautionary Methods

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SECTION 1 INTRODUCTION

The GXR range of generators has been developed to provide repeatability and accuracy to corona treatment applications, and, by using the most current technology in power semiconductors to maximize the efficiency of the corona treatment system. The corona treatment equipment consists of three main parts; a. b. c. Generator HT Transformer Electrode Station

The generator/inverter converts power from the mains input supply to a high frequency supply for production of the corona. The HT transformer converts the generator/inverter output voltage to a sufficiently high voltage to produce corona discharge at the electrode. There are various tappings on the HT transformer in order to obtain optimum matching of the generator to the electrode station (ie, maximum efficiency, minimum power loss). The electrode station consists, basically, of an earthed plane (the base roll), and insulating dielectric (the base roll coating, or in the case of a bare roll treater, the electrode material), an air gap, and a high voltage plane (the electrode). The corona is formed in the air gap between the electrode and the base roll when a high frequency voltage of sufficient level is applied to the electrode.

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SECTION 2 SPECIFICATIONS OPERATING PARAMETERS MODEL GXR TREATMENT POWER INPUT AMPS/PHASE INPUT FREQUENCY INPUT kVA MAXIMUM MAXIMUM OUTPUT VOLTS R.M.S. OUTPUT AMPS R.M.S. OPERATING FREQUENCY 30 3kW 6 40 4kW 8 50 75 100 5kW 7.5kW 10kW 10 12 16

50/60 50/60 50/60 50/60 50/60 Hz Hz Hz Hz Hz 3.6 6.0 9.0 10.5 14 kVA kVA kVA kVA kVA 600 600 600 600 600

16 18 20 30 40 10-25 10-25 10-25 10-25 10-25 kHz kHz kHz kHz kHz

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SECTION 3 INSTALLATION AND CONNECTION OF EQUIPMENT (Before installation check drawings at rear of manual) 3.1 Generator It is essential that the generator is located in a clear space for easy access and for cooling purposes. 3.1.1 Mains Supply (PL1 GX30R only) The generator requires a 3 phase and earth rated as in Section 2. 50/60 Hz supply. Standard voltages 380, 420, 460, 480. Others on request. 3.1.2 SK2 Underspeed Probe Socket SK2 takes a 3 core cable and plug for the speed rotation sensor. 3.1.3 Output to H T Transformer (SK3 GX30R only) The cable supplied with the equipment should be used for generator connection to the HT Transformer. This cable must not be lengthened without reference to Sherman Treaters. Due to the high operating frequency of the inverter, this cable must not be located in steel conduit as the eddy currents induced will reduce the effective inverter treatment power. 3.1.4 SK4 Interlocks and Skip/Treat (a) INTERLOCKS All the treater interlocks (which detect if any windows are open or if extraction has failed etc.) are wired between pins A and B of SK4. Further customer defined interlocks or a momentary normally closed STOP switch may be wired between pins C and D. If not required connect a link between pins C and D. Breaking the link between A and B or C and D will turn the generator off. To re-start the generator, the START button must be depressed.

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Remote start may be installed by connecting a non-latching normally open switch across pins E & F. (b) SKIP/TREAT If gaps are required in the treatment, a proximity sensor may be wired into SK4. (c) AIR FLOW SWITCH

The Air Flow Switch is fitted to all electrode units to ensure that the extract fan (and the pressurisation fan if fitted) is running. Adjustment of the Air Flow Switch may have to be carried out to ensure that the interlock circuit is broken and the generator stops when the extract or pressurisation fan is stopped. The setpoint may be adjusted by removing the Air Flow Switch cover and with the fans running rotating the screw situated in the centre of the switch until the interlock lamp is lit on the generator. Test that the switch is set up correctly by stopping the fan and ensuring the interlock LED is extinguished.

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3.1.5 PL5 Alarm Circuit This generator has been fitted with both high and low alarm relays whose contacts are closed under the following condition:High Alarm : True power exceeds set limit Low Alarm : True power is less than set limit The high alarm output (240Vac)s are connected between pins A and B and low alarm between pins C and D. 3.1.6 Remote/Computer Interfacing With this option, the generator may be monitored and controlled remotely 4-20mA and 0-10v opto-isolated inputs and outputs are provided, as well as STOP, START, RESET and SKIP inputs. Volt free contacts provide status indicating of the generator for rapid and accurate fault diagnosis. A REMOTE/LOCAL SELECT input allows the user to select remotely whether the generator is to be controlled from the generator or from the remote station. Details of the interfacing may be obtained on request. 3.2 H T Transformer Ensure that the cable from the transformer is correctly connected to the generator. Check that the transformer case is firmly connected to the electrode case and earthed, and that the high voltage connection is made from the transformer to the electrode. The transformer should only be operated in the upright position as indicated on the label.

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3.3

Electrode Unit

When lifting the unit it is advised that the lifting eyes are used, as damage may result otherwise. The electrode unit must be mounted so that the rolls are in line with the machine rolls. N.B. It is important that the electrode gap is checked prior to the electrode unit being switched on. All electrode units have the discharge air gap set before they are despatched, however the gap may move out of alignment during transit or installation. Do not switch the generator power on before rechecking that the air gap is correct (see Section 4). Failure to follow these instructions could result in damage to the roll covering or the electrode and could invalidate the warranty on these items. The pneumatic control box should be connected to a lubricated, filtered air supply. Minimum pressure of 60 p.s.i. Maximum 100 p.s.i. Ozone produced by the corona process must be removed from the area by connecting extraction fans to the ports provided on the electrode unit. It is recommended that smooth bore ducting is used, to maintain the efficiency of the extraction. The length of ducting between the electrode station and extraction fans should not exceed 4 metres. Any increase on this will result in a decrease in efficiency. The extraction is monitored by airflow switches on the extraction port which are wired into the generator interlock circuit to prevent start-up of the generators if the extraction is inoperative. Ensure that base roll is securely grounded via brush or slip ring. Resistance < 2.0 ohms. Interlock switches are installed on the doors and electrode assemblies to prevent generator operation when the station is in a non-operational condition. The Base Roll is monitored by a speed sensing circuit which is connected into the interlock circuit, and prevents start-up until roll is rotating. 3.3.1 Setting Nip Roll
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1.

Set nominal air pressure to pneumatic control box i.e. approximately 2 bar. Set nip stops such that the gaps between the nip roll and base roll (at either end of rolls) is slightly less than the material thickness. Do not lock nip stops. Run treater with film and bring nip against stops (with material edges removed). Test rear edges of film for reverse side treatment when running. If no reverse side treatment is present, lock nip stops. If reverse side treatment is in evidence, lower the nip stop 1/6 turn (to decrease gap). Repeat Steps 5 - 7 until OK.

2.

3. 4.

5. 6. 7.

8.

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3.3.2 Doweling of the Nip Arms It is Sherman Treaters normal practice to dowel both nip arms to the torsion bar. One arm is doweled during build at Sherman Treaters. The other is doweled with the nip roll set parallel to the base roll after the treater has been installed in the line and the final alignment of the sideframes and base roll established. Some customers prefer not to dowel the second nip arm but to allow the two nip arms to have slight independent movement. Note: If it is to be doweled then dowel pins should be used and not screws.

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SECTION 4 OPERATING THE EQUIPMENT

In order to obtain optimum treatment from the system it is necessary to optimize the match between the generator and electrode system. This is achieved by selecting the correct tap on the H.T. Transformer (Section 5) and the correct setting of the choke in the generator for the electrode type. The choke is factory-set and should not require adjustment. The equipment is normally set at the factory to ensure maximum corona power when the maximum electrode area is set and the air gap is correct. Normally 1mm for ceramic dielectrics and 2mm for silicone and hypalon dielectrics and Quartz electrodes. Reduction of the electrode area will result in less current being drawn from the generator although there may not be any reduction in treatment level. Care should be taken, however,not to exceed the power handling capability of reduced area electrodes. Frequency adjustment permits a wider range of matching as explained in Section 5. 4.1 Setting Electrodes The air gap between the electrode and the dielectric sleeve may be adjusted to enable different thickness of material to be treated. An excessive gap may result in loss of corona power. Sherman Treaters' standard electrode units are fitted with calibrated dials which provide a direct indication of the air gap. Gap setting mechanisms must be locked after use to prevent inadvertent maladjustment. Careful setting of the gap is essential if even and effective treatment is to be obtained.

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4.2 Initial Switch On Check that all connections have been made as described in Section 3. 4.2.1. OPERATING PROCEDURE. 1. Turn output power control to minimum. 2. Switch on the mains isolator on the door. The mains on lamp, shutdown and low alarm LED's will light. 3. Close the electrodes and start the ozone extraction fans. This will illuminate the interlock closed LED. 4. When the electrode unit base roll is rotating the up to speed LED will illuminate. 5. Press the start button, the shutdown LED will go out, and after a two second delay the output will be enabled. 6. Turn output control to maximum, the treat on LED will light. 7. Switch the frequency/true (kW)/reactive switch to reactive and adjust the frequency control until a zero reading is obtained on the digital display. Switch back to true (kW) position and adjust output control to the required power level. Recheck the reactive power is zero and adjust frequency as required. NOTE: For all extrusion lines, the treater should not be run in the treating mode until the extrusion die has been properly flushed through, and good quality film is procured. This means that the electrode assemblies and nip roll (if fitted) need to be in the parked position, ie, not treating. Failure to comply with these instructions could cause the electrode assemblies and nip roll to be damaged and put out of alignment by lumps.

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If the following LEDs do not illuminate, carry out the suggested checks. MAINS ON INTERLOCKS CLOSED - Check Mains input supply voltage. - Remove SKT4 and check for continuity between pins A and B (electrode interlocks) and pins C and D (customer interlocks and external stops). . . . . Rotation sensor is fitted. Electrode rolls are turning. Line speed circuit is calibrated. If UTS facility is not required, override using SW3-B.(up = override).

UP TO SPEED

If full output power is not available, it is probably due to the generator not being correctly matched to the treater. (See Section 5 for matching). If the POSITIVE MISMATCH or NEGATIVE MISMATCH indicators light, then in the same way, increase the tap for negative mismatch, reduce the tap for positive mismatch. Operate the RESET switch to refresh the MISMATCH indicators. Check that the INTERLOCKS LED extinguishes if the interlocks circuit is broken. 4.3 Normal Operation After Initial Checks . Switch on the mains isolator on the front door. The mains on and low alarm and shutdown LEDs should be lit. . Depress the START button. . Set OUTPUT POWER demand potentiometer to required level. . Depress STOP button to stop treatment. Always use the START and STOP button for all normal starting - stopping. Use the mains isolator only as an isolator for prolonged shutdown. To select Automatic frequency matching SW1- on the inverter PCB should be selected in the down position.

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SECTION 5 MATCHING THE GENERATOR TO THE ELECTRODE It is essential that the generator and electrode unit are matched to achieve maximum efficiency and to maintain correct generator operation. The generator has been designed to operate within set limits of inverter voltage, current and frequency. If the matching is incorrect, the generator will limit the treatment to the load to ensure that the inverter always operates within its safe operating area. No adjustments are required, or should be made, to the inverter itself. As high currents flow in the output cables, it is essential that all connectors and mating surfaces are clean and that connections to the transformer are tight and locked using spring washers. It should be possible to obtain satisfactory matching of the generator to the load simply by selecting the correct tap on the H.T. transformer and by frequency adjustment, by following the procedure in steps 1 to 11 listed below. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Press STOP button Switch off isolator on door Set the electrode gaps required, but not exceeding 2mm Remove the terminal cover from the HT transformer Connect the earth (green/yellow) wire to the stud marked 'E' Connect the black wire(s) to Tap 1 (GX75/100 - 2 black wires) Connect the blue wire(s) to Tap 7 (GX75/100 - Blue & Brown wires) Switch on and set Power potentiometer to maximum. Adjust frequency potentiometer to point where reactive power reads zero, and note the true power reading. If maximum power not acheived then proceed with step 11 Switch generator off and move blue wire(s) (GX75/100 - Blue & Brown wires) to the next lower tap and repeat steps 8 and 9 to determine the tap which gives the maximum output.

Frequency adjustment sets the optimum True Power and Reactive Power values. At best match the Reactive Power should read zero. Note that as the frequency passes optimum the Reactive Power will change polarity. Reactive Power and Frequency are displayed on the Digital Meter by selecting the switch position on the front panel.

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SECTION 6 MAINTENANCE OF SHERMAN GENERATORS & ELECTRODE UNITS When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system. SECTION A SECTION B SECTION C SECTION D ELECTRODE MAINTENANCE DETAILED ELECTRODE MAINTENANCE GX GENERATOR MAINTENANCE FINAL CHECKS

SHEET (A)

GENERATOR CHECK AND CLEAN PERIODS ELECTRODE UNIT CHECK PERIODS ELECTRODE UNIT CLEAN & GREASE PERIODS

SHEET (B) SHEET (C)

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SECTION A Maintenance When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system. Electrode Station The electrode stations should be examined periodically, and accumulations of dust and other particles removed. This should be done using dry, lint free cloths, brushes and suction hose. Base Roll The treater roll may be cleaned using warm, soapy water. From a health and safety viewpoint it is recommended that solvents are not used. Air Gap Adjustment The calibrated gap adjusters on each electrode assembly are used to set the air gap between the electrodes and the treater rolls. The air gap may be selected by the customer although optimum performance is achieved with an air gap of 1.0mm to 2.0mm. Adjustment is made by slackening the locking screw, on the side of the adjuster retainer, and rotating the calibrated dial to the required gap setting, then retighten the locking screw.(Do not slacken the grub screw holding the scale collar to the gap adjuster assembly, as this will disturb the calibration of the scale collar and hence the gap setting. The air gap is set, and the dial calibrated before leaving the factory. NOTE: Check the air gap at both outer edges of the electrode in the line direction to ensure that the tilt of the electrode is correct. This may be adjusted by rotating the tilt adjust bolts located at one side of each electrode assembly.

When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system.
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Pressurised Electrode Station This is a combination of negative pressure for the extraction of ozone, and positive clean air pressure preventing hazardous vapours etc. entering the electrode station. The minimum level of pressure within the station is +0.5mm of water (or a level specified by relevant local regulations), and is achieved with damper valves located within the ductwork between the electrode station and the pressurisation fan, and the electrode station and the ozone extraction fan. It is monitored by pressure differential switches which are wired into the generator interlock circuit to prevent start-up of the generators if pressurisation is not achieved. Generators should not be operated until correct pressurisation of the electrode station is established. It is recommended that smooth bore ducting is used to maintain efficiency. The pressurisation system must have its' own dedicated ducting from its' fan situated in a safe non-hazardous area, to the electrode station. The ozone extraction system must also have its' own dedicated ducting from the electrode station through the fan to atmosphere. The ducting should not be linked into a centralised ducting system as changes to other equipment can upset the pressure balance within the electrode station creating a potentially hazardous situation. The damper valves are required to be fitted no closer to the fans than 6 times the duct diameter. The pressurisation fan inlet filter must be regularly checked and cleaned (refer to Maintenance and Inspection Procedure section of this manual).

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When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system.

Electrode Assembly Removal (ASSEMBLY TYPE UNITS ONLY) The electrode insulator assemblies may be removed for cleaning by turning the slotted screw inside the gap adjuster tube one quarter turn anticlockwise. The insulating blocks may then be cleaned using a clean, dry, lint free cloth. The assembly is refitted and locked in position with one quarter turn clockwise of the mechanism. When an electrode assembly has been removed and refitted it is essential that a resistance check is made for continuity between the HT transformer output and the electrode. The mechanical contact is made by a spring loaded ball and if this is not made arcing can occur at this point causing damage to the macralon and PTFE components of the assembly.

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SECTION B When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system.

Electrode Units 1. Clean dielectric sleeves with soap and water. Replace any sleeves that are damaged. Inspect and clean all ceramic and PTFE insulators. Replace any that are broken or show signs of arcing. Remove HT transformer and clean output insulator. Remove and clean quartz tube assembly units with soap and water. (See Section C for removal). Clean inside and outside of unit. Clean aluminium and stainless steel segments with wire brush and separate any that are corroded together. Clean aluminium 'U' section and multi fin electrodes with wire brush. Clean gap adjusters, tilt screws, tension springs and regrease. Set air discharge gaps by moving the calibrated gap adjusters, and tilt adjusters.

2.

3. 4.

5. 6.

7. 8. 9.

10. Check HT links for tightness on electrode bar, and ensure 40mm spacing to earth. 11. Check speed sensor magnets are in correct order on base roll. ie, red, blue, red, blue (N, S, N, S). 12. Check speed sensor probe is 5mm away from magnets and 1mm for studs and adjust as required. 13. Check pneumatic cylinders for air leaks and repair as required. 14. Check pneumatic open/close operation of unit or assemblies for smooth opening and closing and adjust as required.
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15. Check safety interlock switches are tight. 16. Check for free rotation of base and idler rolls. Replace any worn bearings. 17. Remove HT transformer terminal cover and check tightness of electrical connections. 18. Check ozone extraction ducting for leaks and repair any found. 19. Remove extract fan and clean impeller and fan housing. 20. Remove inlet filter from pressurisation fan and clean (if applicable). 21. Remove pressurisation fan and clean impeller and fan housing (if applicable). 22. Check pressurisation ducting for leaks and repair any found (if applicable). 23. Check gaskets and all seals on station and repair as necessary (if applicable).

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SECTION C When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system.

GX Generator Maintenance 1. 2. 3. 4. 5. Replace any defective LEDs. Check speed circuit operation. See Section D, Para 2 Check that all cooling fans are rotating and impellers are clean. Check all output cables for damage. Check alarm circuit for correct operation, ie, alarm lamp out when digital meter reading is within the limits set by low and high controls and alarm lamp lit when digital meter reading is outside the limits set by low and high controls. Check that all plugs and sockets are tight. Clean inside of generator compartment, checking tightness of all electrical connections. Remove filters and clean. Replace any filters that are damaged. Clean outside of generator.

6. 7.

8. 9.

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SECTION D When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system.

Final Checks 1. Check interlock circuit for correct operation, ie, interlock LED goes out when:a. b. c. 2. any window is opened (if fitted) electrode is opened or rotated ozone extract fan is stopped

With generator on, and electrode unit open, rotate base roll and check that the speed sensor LED lights, and goes out when base roll stops. Adjust speed threshold as in generator manual. Generator and electrode unit handed back to operator, with instructions to operator to check dyne levels of materials when line is running. When line is running check maximum output of generator that can be achieved. Check interlock circuit again as in Para 1. This time check that treatment stops when (a), (b) & (c) are operated.

3.

4.

5.

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SHEET A CUSTOMER MAINTENANCE AND INSPECTION PROCEDURE When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system.

GENERATOR CHECK LIST

MAINTENANCE INTERVAL
No. CLEAN 1 All lamps light up 2 Speed circuit operation 3 4 5 6 7 Daily Weekly 2 Weeks Monthly 3 Months

Rotation of fan All output cables for damage Alarm operation (where fitted) Tighten plugs and sockets Tighten screws and nuts

MAINTENANCE INTERVAL
No. CLEAN 1 Filters 2 3 Daily Weekly 2 Weeks Monthly 3 Months

Outside of generator cabinet Inside of generator cabinet

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SHEET B When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system. CUSTOMER MAINTENANCE AND INSPECTION PROCEDURE ELECTRODE UNIT CHECK LIST
MAINTENANCE INTERVAL
No. CHECK
Weekly 2 Weeks Monthly 3 Months 6 Months Yearly

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 21

Air gap HT links are not arcing HT links are tight HT contact ball HT ball spring for easy movement Magnets/studs on correct end of base roll Box opens and closes freely and easily (if applicable) Pistons and pipes for air leaks Each tube assembly rotates freely Each tube assembly opens/closes freely with pneumatics Window safety switches operate (where fitted) Safety microswitches function correctly All interlocks stop generator when operated Speed probe is 5mm from magnets or 1mm from studs Base and idler rolls rotate freely Ozone duct for leaks Fixing screws are tight Ozone extract fan impeller Pressurisation ducts for leaks (if applicable) Condition of door seals & gaskets Pressurisation fan impeller (if applicable)

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SHEET C CUSTOMER MAINTENANCE AND INSPECTION PROCEDURE When live high voltages are present within this equipment, ALL maintenance must be carried out with the mains supply disconnected from the system.

ELECTRODE UNIT CHECK LIST

MAINTENANCE INTERVAL
No. CLEAN
Weekly 2 Weeks Monthly 3 Months 6 Months Yearly

1 2 3 4 5 6 7 8 9 10 11

Dielectric roll covering All electrode insulators HT transformer insulator Wipe surface of tubes Viewing windows (where fitted) Tube assembly after removal Drain water from air regulator (if fitted) Inside and outside of electrode unit Segments: Discharge surface and movement U-section and Multifin: Discharge surface Pressurisation fan filter (if applicable)

MAINTENANCE INTERVAL
No. GREASE
Weekly 2 Weeks Monthly 3 Months 6 Months Yearly

1 Tilt adjuster (where fitted) 2 Gap adjuster screws 3 Tilt springs (where fitted)

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SECTION 7 DESCRIPTION OF CIRCUIT OPERATION 7.1 Circuit Overview The mains passes through a mains filter for EMC requirements. On operation of the mains isolator on the door, the fan starts and power is fed into the GXR Inverter Control PCB via T1 transformer. If all the interlocks conditions are met, depressing the START BUTTON will operate K1 and after a short delay K2 and K3. The mains is rectified by BR1, creating a DC rail of 330V +30V. The inverter switches this voltage creating a 660V + 60V square wave at its output. L1 smooths the output and C2 decouples it. Feedback control and power measurement is achieved via CT2, the output current transformer and T2, the voltage feedback transformer. To assist the description, the control relays on the inverter control PCB will be denoted by a lower case k, and the relays mounted on the chassis plate by an upper case K. 7.2 Power Supply The GXR Inverter Control PCB is powered via T1, which has four independent ac outputs. These enter the PCB by TB10. When rectified these produce four 24 Vdc supplies. . 24V(A) powers the auxiliary circuits: Interlocks Skip/Treat Sensor Rotations Sensor Indicators on Door

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. +24V(B) and -24V(B) are regulated to produce a dual +15V (B) board supply, used to power all the analogue circuits. . 24V(C) powers the computer interface circuits. The 24V(A) and +24V(B) zero volt lines are linked at the star earth. The 24V(C) supply is completely isolated and floating. 7.3 'Major or Hard' Interlocks Refer to the overall circuit diagram and the relay circuit. The interlocks are powered from 24V(A) via SKT4. If all the treater interlocks (door switches, air flow switches etc.) are closed then 24V flows through the external STOP switch (normally closed) and the local STOP switch and enters the Inverter Control PCB at TB1.5. If all the interlocks and stop switches are closed k6 will operate and the INTERLOCKS LED will illuminate. If none of the thermal switches have opened, k7 will operate. The generator is now in a stand by state. On depression of the START button, K6 closes and a contact from this closes K1, after a short delay to allow C1 to charge up, K4 and K5 close and contacts from these close K2 and K3 allowing full power to the inverter. If any of the interlock switches, stop switches or thermal switches open, then the interlock relay K6 will de-energise and this will then remove the 24 volt supply to K4, K5 and K6 relays and in turn will then de-energise K1, K2 and K3 relays and disconnect the supply to the inverter and the output. To restart the generator, the fault must be remedied and the START button depressed again.

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7.4 'Minor or Soft' Interlocks There are a number of interlocks which prevent the generator from producing an output only while the fault condition exists. It is not necessary to depress the START button again after these faults. 7.4.1 Line Speed A proximity detector is connected to SKT2 to detect the line speed. The pulses are converted into a dc signal which is normally set to 10V at full line speed, by adjusting RV6 until LED2-J and LED3-A are both flashing at the same rate. SW3-A (normally in the up position) is used to select ranges (3-23Hz or 17-380 Hz). If the line speed signal drops below the voltage (UTS limit), k10 de-energises and a NOT UP-TO-SPEED signal is produced. Adjustment of the minimum Up To Speed level is adjusted by RV13. 7.4.2 Positive and Negative Mismatch If the reactive power exceeds a preset value of the full rated output power of the generator, then the positive or negative mismatch relays will operate, depending on the sign of the reactive power signal. For analysis of this fault condition see Section 8. Although the fault signals produced by these circuits last only as long as the fault, the mismatch and shutdown indicators remain on until the reset switch is operated. 7.4.3. Current Trip CT2, detects an overcurrent on the inverter output. This would occur should the output become short circuited, or if all the FETS turned on at the same time. The output of CT2 turns off the output rapidly for a severe overload.

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7.4.4. Auxiliary Shutdown An additional shutdown pin, TB6.6, has been incorporated to allow for any other 'soft' interlocks, one of the gates of IC36 will go high and a shutdown signal will appear on pin 13, causing the pulse width modulation (PWM) circuit to turn off all the FETS. When the shutdown signal returns to a low again, the (PWM) circuit goes through a soft-start whereby the output slowly increases to its normal value, allowing time for continued faults to be detected prior to full power being delivered to the treater. The shutdown indicator will remain on until the reset switch is operated. 7.4.5 Skip/Treat - Optional A skip sensor may be connected to SKT4. If a low voltage is detected, a SKIP/TREAT signal is operated. The skip signal is applied directly to the PWM circuit. It has a fast response on shut down and recovery, enabling accurate and fast SKIP/TREAT sequences. The shutdown indicator is not affected by the SKIP signal.

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7.5

Power Control

The power demand signal is 0-10V for min - max output power. One of three methods of control is selected by SW2: . . . Manual, (switch fully anti-clockwise). Proportional, (switch centre position ). Remote, (switch fully clockwise).

7.5.1 Manual The power demand signal is varied by the power potentiometer on the cabinet door. 7.5.2 Proportional If the line speed signal is set to 10V at full line speed, then the output power is proportional to the line speed, giving full power at full line speed. This enables a constant treatment level to be achieved despite fluctuations in line speed. 7.5.3 Remote (Optional) The remote power demand input is discussed in Section 7.7.1. If this switch is selected then inputs on computer interface will control the output even if the generator is in the local mode. 7.6 Pulse Width Modulation (PWM) Circuit

The power demand signal causes the PWM circuit to switch the inverter at the necessary duty cycle, until the TRUE POWER signal equals the POWER DEMAND signal. Outputs A and B of the PWM circuit have the same pulse width, but are 180o out of phase. There is always a short deadtime between O/P A going low and O/P B going high, and vice versa, to prevent large switching transients.

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The inductor L1 creates a resonant circuit with the capacitance C2 and the impedance of the electrodes in the treater causing a sine wave to appear across the HT transformer input. 7.7 True and Reactive Power Measurement

The O/P voltage and current are sensed by T2 and CT2, multiplied to give true power and conditioned to provide reactive power measurement. They are both calibrated to read 10V at full rated power. The True power signal is used as feedback in the PWM circuit to ensure that the O/P power matches the demand power. A switch is provided on the door to select between true and reactive power. 7.7.1 Remote Overall Circuit diagram shows the remote connections where fitted including the following interfaces: ANALOGUE i/p & o/ps . . . 4 - 20mA or 0-10V Power Demand i/p 4 - 20mA or 0-10V True Power o/p 4 - 20mA or 0-10V Reactive Power o/p

DIGITAL CONTROL SIGNALS i/p Voltage i/p Current 5-24V 2-10mA

REMOTE/LOCAL SELECT REMOTE TREAT/SKIP REMOTE NOT STOP:

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REMOTE START

In remote mode generator may be started using REM START, EXT START or LOCAL START. To ensure generator may only be started remotely, hold REMOTE NOT STOP low until ready to press REMOTE START. Resets POSITIVE and NEGATIVE MISMATCH, TRIP SHUTDOWN, relays and indicators.

REMOTE RESET

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SECTION 8 TROUBLE SHOOTING In the event of a problem, carefully follow the procedures listed below. Bear in mind that HIGH VOLTAGES exist within the inverter cubicle and any checks within the cubicle must be carried out with the MAIN SUPPLY ISOLATED. 30 SECONDS SHOULD BE ALLOWED AFTER ISOLATION OF SUPPLY FOR THE DISCHARGE OF CAPACITORS WITHIN THE UNIT. 8.1 CBI Trips

This will be due to either a faulty bridge rectifier BR1, or a problem with the capacitor precharge circuit. 8.2 Inverter Overtemperature

(i) Check that the fan is operating and all air inlets and outlets are clear. Change the filter if it is excessively dirty. If the fan has failed, check fuse FS1 on the DIN rail. (ii) Check that the the generator is not being exposed to excessive heat. If the problem persists, consult Sherman Treaters Service Department for advice. 8.3 Generator Keeps Tripping

i.e. TRIP light comes on during treatment. Reset generator at low power and set to operational level. If fault persists, consult Sherman Treaters Service Department.

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8.3.1 Poor Match Select correct tap on transformer. Follow procedure described in (Section 5) for optimizing the match. 8.3.2 Incorrect Electrode Gap Reset the gap (Section 4.1) Check that transformer tapping is still optimum. 8.3.3 Fault in Electrode System Check the electrode unit and look for extraneous flashes in the treater during operation (e.g. from leads to case. Check that all the insulators are clean, and the dielectric sleeve and the discharge tubes are clean and not pinholed).

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8.3.4 LED Arrays and SW1, SW2 and SW3 positions Three LED arrays have been included on the PCBs to assist in trouble shooting. These are designated as below:
A B C D E F G H I J A B C D E F G H I J A B C D E F G H I J

LED 1

LED 2

LED 3

LED 1 (GREEN)

A B C D E F G H I J A B C D E F G H I J

24V(A) 15V(B) -15V(B) 15V(C) Interlock Closed Over-temperature 24V(B) Start Relays Closed Line up to Speed Shutdown Positive Mismatch Negative Mismatch Overcurrent Trip Skip Skip Signal Remote Skip/Treat High Alarm Low Alarm Up To Speed Signal

LED 2 (RED)

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LED 3 (GREEN) A B C D E F G H No error driver one No error driver two Treat On Up To Speed Signal Rotation Sensor

I Remote not stop J Remote/Local Select

frequency control SW1-B Not used SW1-C Not used SW1-D Not used SW2 LEFT CENTRE RIGHT

up=man down=auto

Manual Proportional Remote -up=high -down=sensor input -down=override -up=0-10v, down=4-20ma

SW3-A Up To Speed High/Low Frequency SW3-B Up To Speed override SW3-C Skip delay override SW3-D Pwr demand 0-10v/4-20ma

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SECTION 10 PARTS LIST FOR GX30R CABINET DOOR CIRCUIT DESCRIPTION LAMPS LP1 OVERTEMPERATURE LP2 MISMATCH LP3 TRIP LP4 LOW ALARM LP5 HIGH ALARM LP6 SHUTDOWN LP7 UP TO SPEED LP8 TREAT ON LP9 INTERLOCKS LP10 MAINS ON LP1/9 LAMPHOLDER + 24V LAMP LP1/9 24VOLT LAMP LP10 TRANSFORMER LAMPHOLDER+ 6V LAMP LP10 6 VOLT LAMP SWITCHES SW1 START BUTTON (WHITE) + CONTACT BLOCK SW2 STOP BUTTON (RED) + CONTACT BLOCK SW3 RESET/LAMP TEST + CONTACT BLOCK PART NUMBER 122.0109 122.0109 122.0109 122.0109 122.0109 122.0109 122.0110 122.0110 122.0110 122.0111 122.0117 123.0048 122.0121 122.0122 PART NUMBER 122.0115+ 122.0118 122.0135 + 122.0119 122.0114 + 122.0118

(RED) (RED) (RED) (RED) (RED) (RED) (GREEN) (GREEN) (GREEN) (AMBER)

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SWITCHES GX30R SW4 TRUE/ REACTIVE/FREQUENCY SWITCH SW5 ALARM ON/OFF + CONTACT BLOCK

PART NUMBER

122.0120 122.0112 + 122.0118

POTENTIOMETERS RV1 POTENTIOMETER 5K + KNOB KIT (POWER) RV2/3 LOW/HIGH ALARM POTENTIOMETER 5K + KNOB KIT RV4 FREQUENCY. 10 TURN 5K POTENTIOMETER RV4 POTENTIOMETER DIAL MECHANISM DM1 DIGITAL METER PANEL IS1 MAINS ISOLATOR GX30R-100R 101.0059 + 101.0061 101.0109 + 101.0150 101.0089 202.0049 125.0016 122.0092

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PARTS LIST FOR GX40R - 100R FRONT PANEL & DOOR FRONT PANEL POTENTIOMETERS: RV1/2/3/4 10 TURN 5K POTENTIOMETER RV1/2/3/4 POTENTIOMETER DIAL MECHANISM DMI DIGITAL METER LAMPS: LED 1,2,3,4 GREEN LED LED 5,6,7,8,9,10 RED FLASHING LED LAMP1 TRANSFORMER LAMPHOLDER + 6V BULB LAMP1 6V LAMP SW1/2 P/BUTTON DOUBLE HEADED OPERATOR SW3 P/BUTTON BLUE (RESET) SW5 P/BUTTON GREEN (ALARM) SW4 SELECTOR SWITCH TERMINALS SAK 2.5 INVERTER CONTROL PCB (STATE GENERATOR TYPE WHEN ORDERING) 301.4050

101.0089 202.0049 125.0016

123.0067 123.0074 122.0121 122.0122 122.0144 123.0072 123.0073 122.0120 127.0014

301-3061

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CABINET ASSEMBLY GX30R-100R INVERTER HEATSINK CIRCUIT DESCRIPTION GX30R 3KW INVERTER HEATSINK ASSEMBLY GX40R 4KW INVERTER HEATSINK ASSEMBLY GX50R 5KW INVERTER HEATSINK ASSEMBLY GX75R 7.5KW INVERTER HEATSINK ASSEMBLY GX100R 10KW INVERTER HEATSINK ASSEMBLY MAINS FILTER MF1 MAINS FILTER GX30R MF1 MAINS FILTER GX40/50R MF1 MAINS FILTER GX75/100R TRANSFORMERS T1 PSU TRANSFORMER T2 VOLTAGE FEEDBACK TRANSFORMER T3 MAINS INPUT TRANSFORMER GX30R T3 MAINS INPUT TRANSFORMER GX40/50R T3 MAINS INPUT TRANSFORMER GX75/100R CT1/2 CURRENT TRANSFORMERS GX30/40/50R LI INDUCTOR GX30/40/50R L1 INDUCTOR GX75/100R CT1/2 CURRENT TRANSFORMERS GX75/100R 111.0107 111.0108 111.0114 111.0110 111.0112 111.0085 111.0109 111.0113 111.0111 103.0155 103.0189 103.0197 PART NUMBER 103.0194 103.0165A 103.0234 103.0196 103.0196

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CIRCUIT BREAKER CB1 CIRCUIT BREAKER GX30/40/50R CB1 CIRCUIT BREAKER GX75/100R CONTACTORS K1/3 CONTACTOR GX30/40/50R K2 CONTACTOR GX30/40/50R K1/2/3 CONTACTOR GX75/100R K2 AUX CONTACT BLOCK GX75/100R K5 24V RELAY GX40-100R K6/7 24V ALARM RELAYS + K4 RELAY GX40-100R K5 RELAY BASE GX40-100R K6/7/8 RELAY BASE (DPCO) GX40-100R

PART NUMBER 122.0106 122.0125

122.0107 122.0108 122.0123 122.0124 122.0131 122.0133 122.0132 122.0134

CAPACITORS C1 CAPACITORS 1500 uF - GX30R C2 CAPACITORS 0.22uF GX30/40/50R C2 CAPACITORS 0.22uF GX75/100R CAPACITOR GX30R 102.0044 102.0099 102.0029 102.0028

RESISTORS R1/2/3 RESISTOR 100R 25W R4 RESISTOR 2K2 25W 101.0149 101.0113

FUSES

FS1-4 FUSE HOLDER FS1/2 FUSE 1AMP FS1-4 PCB FUSES 2 AMP FS3/4 FUSE 500 MAMP GX40-100R PLUGS AND SOCKETS PL1 MAINS 5 WAY PLUG GX30R SK1 MAINS 5 WAY SOCKET GX30R SK3 HT 7 WAY SOCKET GX30R

123.0058 123.0012 123.0063 122.0068

121.0011 121.0012 121.0083

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PL5 ALARM 7 WAY PLUG GX30R SK5 ALARM 7 WAY SOCKET GX30R SK2 ROTATION SENSOR 3 WAY SOCKET - GX30-100R SK4 INTERLOCKS 14 WAY SOCKET GX30-100R SK5 ALARMS 7 WAY SOCKET GX40-100R PL4 INTERLOCKS 14 WAY PLUG GX30-100R PL5 ALARM 7 WAY PLUG GX40-100R FANS FAN 230VAC GX40/50R FAN FILTER KIT GX30R FILTER GX40-100R SUPPRESSOR K1,2,3 GX75/100R EMC SHIELD BEADS (SINGLE) SHIELD BEADS (DOUBLE) PCB SURGE SUPPRESSOR PCB1 PCB SURGE SUPPRESSOR PCB2 PCB SURGE SUPPRESSOR PCB3&4 TERMINALS TERMINAL SAK 6N GX40/50R TERMINAL SAK16 GX75/100R HT TRANSFORMERS HT 3 GX30/40/50R HT 8 GX75/100R HT10 HT11

121.0003 121.0004 121.0029 121.0010 121.0014 121.0056 121.0015

124.0028 124.0017 202.0024 122.0155

132.0124 132.0125 301.6154 301.6155 301.6156

127.0043 127.0031

111.0051 111.0079 111.0082 111.0126

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SECTION 11 Procedure for Setting Reactive Power to Zero

The generator and spare PCB's are sometimes sent to customers without an electrode unit, and it may be necessary to calibrate the reactive power. This is done by the following procedure. 1. Switch the generator into manual frequency control. This is done by switching SW1-A (brown switch) to the up position. Set frequency potentiometer situated on the front panel fully anticlockwise. Set output power potentiometer to minimum. Switch on generator. Adjust output potentiometer to maximum. Increase frequency until maximum true power is reached. Switch to reactive power and the reading should be zero. If not zero adjust RV3 potentiometer situated on the PCB so that the reactive reading is zero.

2.

3. 4. 5. 6. 7. 8.

Note: If the generator should trip on mismatch during step 6 then reset the generator and note the reactive power reading and adjust RV3 until reactive zero. Then do steps 6,7 and 8. Auto frequency control When the reactive is zero and tru power is at maximum switch SW1-A to the down position to run the generator in auto frequency. (This makes the frequency potentiometer inoperative.) The reactive power will have a small reading but this is normal.

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MACHINERY SAFETY 1. Corona treatment equipment operates at very high voltages (up to 15000 Volts) at electrodes. It is essential that the utmost caution is taken when operating and maintaining equipment, where dangerous voltages are present they are indicated by the hazardous voltage warning label ISO 3864 No. B.3.6.

No access is permitted to the area indicated by this symbol UNLESS the power supply is isolated.

2. The treatment process produces ozone gas as a by product. It is the customers responsibility to ensure that the unit is connected to a suitable extraction system and or catalytic converter constructed from corrosion resistant materials. Ozone extraction outlets are identified by the above label. (See Appendix 1.)

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3. The generator is equipped with a dust filtration system indicated by the caution symbol ISO 3864 No. B.3.1 symbol. If this system blocks, see routine maintenance section as the unit may overheat.

4. When isolating the Generator supply a small time delay of <5 seconds is needed for power to drain from capacitors via leakage resistors. Service engineers opening the doors should be aware of this. 5. Care must be taken to avoid injury from moving parts, such as rotating rolls, moving electrode assemblies and sensor probes at roll ends. Where risk is considered high guards are fitted. 6. Some machines are designed to be open construction. It is the customers responsibility to ensure access is safe. Fence type guards or other protection can be ordered separately at order placement or subsequently. NB Sherman treaters cannot specify guarding of interfaces between their machinery and the machinery into which it is to be incorporated because of the unique requirements of each installation. Therefore Sherman Treaters have supplied machinery with residual mechanical and electrical risks which must be safe-guarded by the user. Access to Sherman Treaters machinery must be prevented at all times when the HT electrodes are energised.

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12 Ozone: Health Hazards and Precautionary Methods Guidance Note EH38 from the Health and Safety Executive

OZONE : Health Hazards and Precautionary Measures

Environmental Hygiene Series 38 (July 1983)

These Guidance Notes are published under five subject headings: Medical, Environmental Hygiene, Chemical Safety, Plant and Machinery and General.

INTRODUCTION 1. This guidance note contains information on the principal hazards to health from ozone and on potential sources of exposure. General advice on precautionary measures, control techniques and legal requirements is given. 2. Ozone, O3, is a toxic gas possessing a distinctive odour and is a normal constituent of the earths atmosphere. Ozone is produced deliberately for a variety of industrial purposes and is also produced naturally from oxygen whenever ultra-violet radiation or electrical discharges occur, e.g. at high altitudes or by the action of lightning. Such natural occurrence is unlikely to produce concentrations hazardous to man. 3. Because of its strong tendency to decompose and to release oxygen, ozone is extremely reactive and is a powerful oxidising agent which reacts explosively with oil and grease. Nevertheless it can be used with safety in industry. For example, since it readily oxidises organic matter, it is used as a bactericide and algaecide. 4. Ozone itself is a distinctly blue coloured gas (bp 111.9C) and is about one and a half times heavier than air (density 2.144g/l). Ozone is used as ozonised air, a colourless gas produced when ozone is generated from part of the oxygen in air (see para 13). Ozone cannot be stored or transported in vessels because it decomposes spontaneously in the presence of oxidisable impurities, humidity and solid surfaces. The rate of decomposition increases with temperature. 5. Background concentrations in our immediate atmosphere vary as a function of season, weather conditions, altitude and humidity.

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49 EFFECTS OF OZONE 6. Low concentrations of ozone have a significant effect upon textiles, fabrics, organic dyes, metals, plastics and paints and cause the characteristic cracking of stressed rubber, commonly called weathering. A few substances, however, are resistant to the oxidising effect of ozone and these include glass and some stainless steels. 7. The acute toxicity of ozone to man has long been recognised and is well documented1-8. The symptomatic and clinical effects of ozone at various concentrations are summarised in Table 1. Ozone is irritant to mucous membranes of eyes and respirator tract, and high concentrations can cause pulmonary oedema. 8. It is possible that there are secondary sites of reaction to ozone characterised by a defect in oxygen dissociation from oxyhaemoglobin in the tissues. Even at an exposure level of 0.1ppm ozone, premature ageing may result in man if exposure is sufficiently prolonged. EXPOSURE LIMITS 9. The Health and Safety at work etc Act 1974 requires every employer to ensure, so far as is reasonably practicable, the health of all his employees and others who may be affected by the work he undertakes. The Act also places duties in respect of health and safety matters on the self-employed. The Factories Act 1961 requires factory occupiers to take all practicable measures to protect employed persons against inhalation of fume. The general policy adopted by the Health and Safety Executive is that exposure to hazardous substances should be kept at low as is reasonably practicable and in any case exposure should be kept within published standards by the application of engineering controls or other suitable control techniques. The Health and Safety Executive publishes, in guidance notes in the RH series, information on exposure limits applied in the UK. 10. The recommended exposure limit for ozone is 0.1ppm (0.2mg/m) calculated as an 8-hour timeweighted average concentration. There is also a short-term exposure limit for ozone of 0.3ppm (0.6mg/m) calculated as a 15-minute time-weighted average concentration. SOURCES OF EXPOSURE 11. Ozone is made using ultra-violet radiation or electrical discharge either intentionally for the purpose of a specific process or incidentally to a process. It is an unstable substance but is rate of decomposition varies widely according to temperature and humidity. A given ozone output yielding a faint trace of ozone in a workroom atmosphere on a humid day may created an undesirable concentration on a dry day. INTENTIONAL PRODUCTION 12. Ozone is usually produced intentionally by silent electrical discharge in air. Alternative means of production such as bombardment of air with ultra-violet or ionising radiation, or electrolysis of cooled sulphuric acid , are uncommon in practice. 13. There are basically three types of ozone generator in use, working at: (a) Atmospheric pressure typically a box through which material to be treated with ozone is passed, and in which a silent electrical discharge is initiated through the air be means of metal electrodes. This system is often used for surface treatment of plastic film. (b) Reduced pressure found in swimming pool disinfection plants whereby dried air is drawn through glass tubes across which is a silent electrical discharge is struck. The reduced pressure is generated by a sidestream from the circulating pool water forming a venturi vacuum. (c) Positive pressure found in potable water treatment plants and throughout industry generally. Dried air is blown through glass tubes across which a silent electrical discharge is struck and this ozonised air emerges at positive pressure. 14. The processes for which ozone is produced are outlined below.

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50 SURFACE TREATMENT 15. Various industries which manufacture or use plastic packaging in its various forms use ozone to pretreat the plastic surface immediately before printing. ELECTRICAL DISCHARGES 16. Ozone is generally produced around high voltage equipment and by electrical discharges in specific processes e.g. (a) Arc welding reactive metals such as aluminium and titanium, and also stainless steel are arc welded in an inert shield of argon or carbon dioxide. The intense radiation from the arc produces significant quantities of ozone. (b) Static eliminators are often used in industry to remove static electricity from recently moulded plastic articles, and continuous use of them in a poorly ventilated room could lead to the buildup of an irritating level of ozone above the recommended exposure limit. The main factor which determines the amount of ozone produced is the voltage across the collector plates; the higher the voltage the more ozone is produced. (c) Electrostatic precipitators are used to remove dust and some airborne contaminants from the air and they produce ozone also. More ozone is produced if there are rough or sharp edges on, for example, new metal parts since intense local voltage gradients are produced.

VENTILATION 17. Areas into which ozone may escape must be equipped with adequate ventilation and extraction facilities. In ozone plant rooms, it is recommended that ten changes of room air per hour be achieved to enable dangerous accumulations of gas to be dispersed within a few minutes. 18. Ozone should be prevented from entering the workroom air by the use of exhaust appliances placed close to the source of emission. The ozone may then be passed through appropriate filters before discharge to a safe place in the open air. In the case of ozonators operating under negative pressure, the process acts as its own exhaust ventilator. In the case of atmospheric pressure ozonators, effective local exhaust ventilation is necessary because the ozonators are not enclosed. Cinema projection lamps should present no ozone hazard provided adequate mechanical exhaust ventilation is fitted to the lamp housing and the exhausted air is vented to a safe place. Many processes incidentally producing ozone (e.g. welding, ultra-violet curing inks) will have some ventilation provided to deal with other problems from process. SAFE SYSTEMS OF WORK 19. In order to ensure that plant and processes are properly operated and controlled to minimise risk to health, satisfactory safe systems f work need to be established and maintained by means of appropriate training and supervision. 20. All people operating ozone plant should be given full training in all aspects of the operation of the ozonator and associated equipment and should be trained in emergency and first aid procedures. Emergency action plans should be prepared for all sites where ozone is generated deliberately in potentially hazardous quantities. 21. Special care may be required when opening sealed plant for maintenance purposes. Guidance Note GS510 should be consulted for detailed advice on permit-to-work systems and precautions on entry into confined spaces. 22. Work on ozone plant should only be undertaken by a person specifically authorised to do the work. Such a person should be trained and be competent to do the work in a safe manner. When carrying out repairs or maintenance work on an ozonator, the ozonator transformer must be isolated and locked off, and a permit to work must be issued, to avoid risks from ozone and from electrical hazard. 23. The cleaning materials used for cleaning ozone units and pipework must be free from oil or grease.

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51 24. In the event of an ozone leak a plant restart should not be attempted until the source of leakage has been investigated and rectified. Leak detection by nose is not satisfactory because even slight leaks cause the sense of smell to be numbed and lead to the false conclusion that a leak no longer exists. 25. Appropriate warning signs indicating the presence of a potential toxic gas hazard should be displayed on ozone plant access doors or in passageways leading to the plant room. MONITORING 26. Ozone detectors may be used to provide audible and visual warnings of ozone leaks. Such alarm signals may be used to initiate emergency procedures, or to automatically turn on plant room ventilation and shut down the ozonator. Ozone-in-air monitors are essential in plant rooms where ozonators and associated equipment operate under positive pressure, because of the greater risk of ozone leakage outward. The monitors in such situations should actuate automatic ozonator shut down at 0.3ppm ozone or less, while actuating warning alarms at 0.1ppm or less. 27. Minor ozone leaks can be detected and located by means of moist starch/potassium iodide paper which turns blue on exposure to ozone. 28. It is essential to carry out regular testing and calibration of all sensor equipment used. EXHAUST EMISSION 29. Process gas venting to atmosphere should pass through an ozone destructor device or be released in such a way as to present no hazard. A destructor is a catalyst filter or other device which causes ozone to decompose in a controlled manner to oxygen. Provided the discharge point allows adequate dilution a destructor device may not be necessary. If a catalyst bed, for example activated carbon, is used as an ozone destructor it is possible that the bed could become exhausted during a period of operation and this should be borne in mind when arranging maintenance schedules. 30. Deflection weather caps are not recommended for discharge stacks since these hinder dispersal. Vertical discharge stacks are recommended with a discharge velocity of 15-20m/s to aid dispersal and avoid re-circulation into buildings. Stacks and extraction vents should be carefully sited so that they do not feed fresh air ventilation intakes. 31. The control of ozone input to a process is crucial since excess ozone can lead to high levels of vented ozone. 32. Activated carbon filters must under no circumstances be exposed to ozone concentrations higher than 20g/m since the reaction may become auto-accelerated and lead to an explosion. The automatic shutdown is a safeguard against this risk. FIRST AID 33. If a person is overcome by ozone, the following precautions should be adopted: (a) Remove the patient to a warm uncontaminated atmosphere and loosen tight clothing at the neck and waist. (b) Keep the patient at rest. (c) If the patient has difficulty in breathing, oxygen may be administered provided that a suitable apparatus and a trained operator are available. (d) If breathing is weak or has ceased, artificial respiration should be started. The mouth-to-mouth or mouth-to-nose methods are preferred. (e) Seek medical aid. 34. Ozone poisoning should be treated symptomatically. This may include bed rest, analgesics to relieve pain, and antibiotics as may be prescribed by a medical practitioner.

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52 SAMPLING AND ANALYTICAL METHODS 35. Sampling strategies to monitor the extent of exposure to ozone or to assess compliance with exposure limits should be carefully planned and the advice of an occupational hygienist may prove useful. Short-term sampling may be used to identify peak exposures and to assist in the prevention of acute gassing incidents. It may not be valid, however, to use the results of such sampling for the determination of time-weighted average long-term exposures. Personal atmospheric sampling is to be recommended when assessing the actual pattern and duration of exposure. (Further information is contained in Health and Safety Executive guidance notes on Exposure Limits). 36. The traditional method of determining ozone in air may be used12 but continuous ozone monitors are now available which use a variety of techniques including onemiluminescence, ultra-violet photometry and electro-onemical cells. Relatively inexpensive gas detector tubes are also available. These are ideal for spot check, provided that interfering gases, such as oxidising agents, are known to be absent. STATUTORY REQUIREMENTS 37. The general duties of employers, the self-employed, manufacturers, suppliers and of employees at work are contained in the Health and Safety at Work etc Act 1974. Other relevant statutory provisions include the Factories Act 1961, the Offices, Shops and a Railway Premises Act 1963 and the various regulations and orders made under these Acts. The following is a brief summary of the principal requirements with regard to potential ozone health risks: (a) Health and Safety at work etc Act 1974 s.2 & 3 s.6 s.7 general duties of employers and the self-employed general duties of manufacturers general duties of employees

(b) Factories Act 1961 s.4 s.30 s.63 provision of ventilation dangerous fumes removal of dust of fumes

(c) Offices, Shops and Railway Premises Act 1963 s.7 provision of ventilation

(d) The Shipbuilding and Ship-Repairing Regulations 1960 Regulation 53 The Iron & Steel Foundries Regulations 1953 Regulation 7 The Non-Ferrous Metals (Smelting and Founding) Regulations 1962 Regulation 11 The Electricity (Factories Act) Special Regulations 1944 The Notification of Accidents and Dangerous Occurrences Regulations 1980 The Health and Safety (First Aid) Regulations 1981.

NOTE : FOR SAFETY REASONS IT IS RECOMMENDED THAT A SHERMAN TREATERS OZONE DESTRUCT SYSTEM BE FITTED TO ANY TREATER STATION

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THIS EQUIPMENT WAS SUPPLIED TO YOU BY:

S C

Corona Supplies Ltd

for all your corona needs
Unit G Howland Road Business Park Thame Oxon OX9 3GQ. UK. Telephone: +44 (0) 1844 261779 Fax: +44 (0) 1844 358187 E-mail: sales@coronasupplies co.uk

FOR FURTHER ASSISTANCE, PARTS OR SERVICE PLEASE CONTACT US IMMEDIATELY

THANK YOU

GX30R to GX100R - English